engine overheat MERCEDES-BENZ ML320 2002 W163 Owner's Manual

87 Instrument cluster
Te ch n i c a l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index Clock (13)
Adjusting clock (instrument cluster activated):
Minute: Pull out knob (2) and turn it to the right.
Hour: Pull out knob (2) and turn it to the left.
Coolant temperature gauge (1)
During severe operating conditions and stop-and-go city
traffic, the coolant temperature may rise close to the red
marking.
The engine should not be operated with the coolant
temperature in the red zone. Doing so may cause
serious engine damage which is not covered by the
Mercedes-Benz Limited Warranty.
Wa r n i n g !
• Driving when your engine is badly overheated
can cause some fluids which may have leaked
into the engine compartment to catch fire. You
could be seriously burned.• Steam from an overheated engine can cause
serious burns and can occur just by opening
the engine hood. Stay away from the engine if
you see or hear steam coming from it.Turn off the engine, get out of the vehicle and do
not stand near the vehicle until it cools down.

178 Catalytic converter
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data Instruments
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cluster displayPractical hints Car care Index
Catalytic converter
Your Mercedes-Benz is equipped with monolithic type
catalytic converters, an important element in
conjunction with the oxygen sensors to achieve
substantial control of the pollutants in the exhaust
emissions. Keep your vehicle in proper operating
condition by following our recommended maintenance
instructions as outlined in your Service Booklet.Caution!
To prevent damage to the catalytic converters, use only
premium unleaded gasoline in this vehicle.
Any noticeable irregularities in engine operation should
be repaired promptly. Otherwise, excessive unburned
fuel may reach the catalytic converter causing it to
overheat, which could start a fire.
Wa r n i n g !
As with any vehicle, do not idle, park or operate
this vehicle in areas where combustible materials
such as grass, hay or leaves can come into contact
with the hot exhaust system, as these materials
could be ignited and cause a vehicle fire.

185 Automatic transmission
Te ch n i c a l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index Maneuvering
To maneuver in tight areas, e.g. when pulling into a
parking space, control the vehicle speed by gradually
releasing the brakes. Accelerate gently and never
abruptly step on the accelerator.
To rock a vehicle out of soft ground (mud or snow),
alternately shift from forward to reverse, while applying
slight partial throttle.
Rocking a vehicle free in this manner may cause the
ABS or traction system malfunction indicator lamp to
come on. Turn off and restart the engine to clear the
malfunction indication.Towing a trailer
If the transmission hunts between gears on inclines,
manually shift to a lower gear (select “4”, “3”, “2”
or “1”). A lower gear and reduction of speed reduces the
chance of engine overloading and / or overheating.
At very steep inclines, not manageable with selector
lever in position “1”, switch transfer case to LOW
RANGE, see page 227 for instructions on how to engage
LOW RANGE.
For instructions on trailer towing refer to page 209.
Wa r n i n g !
Getting out of your vehicle with the selector lever
not fully engaged in position “P” is dangerous.
Also, when parked on an incline, position “P” alone
may not prevent your vehicle from moving,
possibly hitting people or objects.Always set the parking brake in addition to shifting
to position “P”, see page 191 for parking brake. When parked on an incline, also turn front wheel
against curb.
Wa r n i n g !
When leaving the vehicle always remove the key
from the steering lock, and lock the vehicle. Do not
leave children unattended in the vehicle, or with
access to an unlocked vehicle. Children could move
the gear selector lever from position “P”, which
could result in an accident or serious injury.

193 Driving instructions
Te ch n i c a l
data Instruments
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cluster displayPractical hints Car care Index Power assistance
BrakesExcessive use of road salt and other snow melting
chemicals spread on roads during the winter months
may cause a build up of moisture or residue to form on
the braking components. This build up or residue could
cause light corrosion of the braking components if the
vehicle is parked with the brakes cold. Apply steady and
even braking pressure when stopping the vehicle to
warm up and dry the brake components.
Important!
Please pay attention to the function of the brake assist
system (BAS), see page 217.
The condition of the parking brake system is checked
each time the vehicle is in the shop for the required
maintenance service.
If the parking brake is released and the brake warning
lamp in the instrument cluster stays on and there is no
audible warning (EBP), the brake fluid level in the
reservoir is too low.
Brake pad wear or a leak in the system may be the
reason for low brake fluid in the reservoir.
Have the brake system inspected at an authorized
Mercedes-Benz Light Truck Center immediately.
Wa r n i n g !
When the engine is not running, the brake and
steering systems are without power assistance.
Under these circumstances, a much greater effort is
necessary to stop or steer the vehicle.Wa r n i n g !
After driving in heavy rain for some time without
applying the brakes or through water deep enough
to wet brake components or salty road conditions,
the first braking action may be somewhat reduced
and increased pedal pressure may be necessary to
obtain expected braking effect. Be sure to maintain
a safe distance from vehicles in front.Resting your foot on the brake pedal will cause
excessive and premature wear of the brake pads.It can also result in the brakes overheating thereby
significantly reducing their effectiveness. It may
not be possible to stop the vehicle in sufficient time
to avoid an accident.

194 Driving instructions
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data Instruments
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cluster displayPractical hints Car care Index
All checks and service work on the brake system should
be carried out by an authorized Mercedes-Benz Light
Truck Center.
Install only brake pads and brake fluid recommended by
Mercedes-Benz.Caution!
When driving down long and steep grades, relieve the
load on the brakes by shifting into a lower gear to use
the engine’s braking power. This helps prevent
overheating of the brakes and reduces brake pad wear.
After hard braking, it is advisable to drive on for some
time, rather than immediately parking, so the air stream
will cool down the brakes faster.
Driving off
Apply the service brakes to test them briefly after
driving off. Perform this procedure only when the road
is clear of other traffic.
Warm up the engine smoothly. Do not place full load on
the engine until the operating temperature has been
reached.
When starting off on a slippery surface, do not allow one
drive wheel to spin for an extended period with the ESP
switched off. Doing so may cause serious damage to the
drive train which is not covered by the Mercedes-Benz
Limited Warranty.
Wa r n i n g !
If other than recommended brake pads are
installed, or other than recommended brake fluid
is used, the braking properties of the vehicle can be
degraded to an extent that safe braking is
substantially impaired. This could result in an
accident.

212 Driving instructions
Te ch n i c a l
data Instruments
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cluster displayPractical hints Car care Index
Towing a trailer
There are many different laws, including speed limit
restrictions, having to do with trailer towing. Make sure
that your rig will be legal, not only for where you reside,
but also for where you will be driving. A good source for
this information can be the police or local authorities.
Before you start driving with the trailer, check the
trailer hitch, break-away switch, safety chains, electrical
connections, lighting and tires. Also adjust the mirrors
to permit unobstructed view beyond rear of trailer.
If the trailer has electric brakes, start your vehicle and
trailer moving slowly, and then apply only the trailer
brake controller by hand to be sure the brakes are
working properly.
When towing a trailer, check occasionally to be sure that
the load is secure, and that lighting and trailer brakes
(if so equipped) are functioning properly.
Always secure items in the trailer to prevent load shifts
while driving.
Take into consideration that when towing a trailer, the
handling characteristics are different and less stable
from those when operating the vehicle without a trailer.
It is important to avoid sudden maneuvers.The vehicle and trailer combination is heavier, and
therefore is limited in acceleration and climbing ability,
and requires longer stopping distances. It is more prone
to reacting to side wind gusts, and requires more
sensitive steering input.
In order to gain skill and an understanding of the
vehicle’s behavior, you should practice turning,
stopping and backing up in an area which is free from
traffic.
If possible, do not brake abruptly, but rather engage the
brake slightly at first to permit the trailer to activate its
brake. Then increase the braking force.
Caution!
If the trailer should begin to sway, reduce the vehicle’s
speed and use the brake controller by hand to straighten
out the vehicle and trailer. In no case should you
attempt to straighten out the tow vehicle and trailer by
increasing the speed or oversteering and stepping on
the brakes.
If the transmission hunts between gears on inclines,
manually shift to a lower gear (select “4”, “3”, “2”
or “1”). A lower gear and reduction of speed reduces the
chance of engine overloading and / or overheating.

213 Driving instructions
Te ch n i c a l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index At very steep inclines, not manageable with selector
lever in position “1”, switch transfer case to LOW
RANGE, see page 227 for instructions on how to engage
LOW RANGE.
When going down a long hill, shift into a lower gear and
use the engine’s braking effect. Avoid riding the brakes,
thus overheating the vehicle and trailer brakes.
If the engine coolant rises to an extremely high
temperature (coolant temperature needle approaching
the red zone) when the air conditioner is on, turn off the
air conditioner. Engine coolant heat can be additionally
vented by opening the windows, switching the climate
control fan speed to high and setting the temperature
control to the maximum hot position.
Extreme care must be exercised since your vehicle with
a trailer will require additional passing distance ahead
than when driving without a trailer. Because your
vehicle and trailer is longer than your vehicle alone, you
will also need to go much farther ahead of the passed
vehicle before you can return to your lane.Parking
Wa r n i n g !
To reduce the risk of personal injury, or damage to
the vehicle powertrain, as a result of vehicle/trailer
movement, always:1. Keep right foot on brake pedal.2. Shift gear selector lever to position “N”.3. Have a second person place wheel chocks on
downhill side of left and right trailer wheels.4. Slowly release brake pedal and let vehicle and
trailer roll into chocks until stopped.5. Firmly depress parking brake pedal.6. Move gear selector lever to position “P”.7. On inclines turn front wheels towards the road
curb.

221 Driving systems
Te ch n i c a l
data Instruments
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cluster displayPractical hints Car care Index Four-wheel electronic traction system (4-ETS+)
With the key in steering lock position 2, the yellow
4-ETS+ malfunction indicator lamp{ and the 4-ETS+
warning lampv come on and should go out when
the engine is running.
The 4-ETS+ improves vehicle’s ability to utilize available
traction, especially under slippery road conditions. The
brakes are applied to the spinning wheel and power is
transferred to the wheel(s) with traction.
The traction control engages at vehicle speeds up to
approx. 24 mph (40 km / h), and switches off at
50 mph (80 km / h).
The 4-ETS+ warning lampv, located in the
speedometer dial, starts to flash at any vehicle speed, as
soon as the tires lose traction and the wheels begin to
spin.
Important!
If the 4-ETS+ warning lampv flashes:
•During take-off, apply as little throttle as possible.
•While driving, ease up on the accelerator.
•Adapt your speed and driving to the prevailing road
conditions.4-ETS+ Control
If the yellow 4-ETS+ malfunction indicator lamp{
comes on while the 4-ETS+ warning lampv flashes,
the electronic traction system is being switched off
temporarily to prevent overheating of the drive wheel
brakes.
If the 4-ETS+ malfunction indicator lamp{ comes on
with the engine running, a malfunction has been
detected.
Have the 4-ETS+ checked at your authorized
Mercedes-Benz Light Truck Center as soon as possible.
With the ABS malfunctioning, the 4-ETS+ is also
switched off.
Caution!
If the vehicle is towed with the front axle raised (see
towing the vehicle on page 277), or when testing the
parking brake on a brake test dynamometer, the engine
must be shut off (key in steering lock position 0 or 1).
Otherwise, the electronic traction system will
immediately be engaged and will apply the rear wheel
brakes.

245 Malfunction and indicator lamps
Te ch n i c a l
data Instruments
and controlsOperation DrivingInstrument
cluster displayPractical hints Car care Index Seat belt warning lamp
With the key in steering lock position 2, the
seat belt warning lamp comes on for a short
time if the driver’s seat belt is not fastened.
After starting the engine, the warning lamp remains
illuminated for a short time to remind the driver and
passengers to fasten seat belts.
Charge indicator lamp
Should the charge indicator lamp fail to
come on prior to starting when the key is in
steering lock position 2 or should it fail to go
out after starting or during operation, this indicates a
malfunction which must be repaired at an authorized
Mercedes-Benz Light Truck Center immediately.If the charge indicator lamp comes on while the engine
is running, this may indicate that the poly-V-belt has
broken. Should this condition occur, the poly-V-belt
must be replaced before continuing to operate the
vehicle. Otherwise, the engine will overheat due to an
inoperative water pump which may result in damage to
the engine.
Do not continue to drive the vehicle with the charge
indicator lamp illuminated. Doing so could result in
serious engine damage that is not covered by the
Mercedes-Benz Limited Warranty.

246 Malfunction and indicator lamps
Te ch n i c a l
data Instruments
and controlsOperation DrivingInstrument
cluster displayPractical hints Car care Index
Low engine oil level warning lamp
With the key in steering lock position 2, the
oil level warning lamp comes on and should
go out when the engine is running.
If the warning lamp does not go out after starting the
engine, or comes on with the engine running and at
operating temperature, the engine oil level has dropped
to approximately the minimum mark on the dipstick.
When this occurs, the warning lamp will first come on
intermittently and then stay on if the oil level drops
further.
If no oil leaks are noted, continue to drive to the nearest
service station where the engine oil should be topped to
the “full” mark on the dipstick with an approved oil.
The low engine oil level warning light should not be
ignored. Extended driving with the light illuminated
could result in serious engine damage that is not
covered by the Mercedes-Benz Limited Warranty.
In addition to the warning lamp, the engine oil level
should be periodically checked with the dipstick or via
the oil level indicator in the odometer display field, for
example during a fuel stop, or before a long trip (see
engine oil level indicator on page 96 and checking
engine oil on page 255).Low engine coolant level warning
When the coolant level warning lamp comes
on while driving, then the coolant level has
dropped below the required level, or the
coolant temperature is in the red zone. If no leaks are
noticeable and the engine temperature does not
increase, continue to drive to the nearest service station
and have coolant added to the coolant system, see
page 256. If the engine temperature reaches the red
zone, move vehicle to an area which is in a safe distance
from the roadway and turn off the engine. Also see
coolant temperature gauge on page 87.
The low engine coolant level warning should not be
ignored. Extended driving with the symbol displayed
may cause serious engine damage not covered by the
Mercedes-Benz Limited Warranty.
In cases of major or frequent minor coolant loss, have
the cooling system checked at your authorized
Mercedes-Benz Light Truck Center as soon as possible.
Notes:
Do not drive without coolant in the cooling system. The
engine will overheat causing major engine damage.
Monitor the coolant temperature gauge while driving.